Collapsible-reusable-returnable-recyclable die cut, self locking corrugated carton

ABSTRACT

A collapsible-reusable-returnable-recyclable die cut, self locking corrugated carton is disclosed. An embodiment includes a plurality of side panels attached to each other by way of corrugated folding lines, and a plurality of bottom panels attached to respective side panels by way of another set of corrugated folding lines. In the unfolded state, the side and bottom panels are adapted to lie substantially on the same plane. In the folded state, the side panels area adapted to form sides of the carton, the bottom panels are adapted to form a bottom of the carton, and at least a pair of the bottom panels are adapted to interlock. Any one or more of the panels may include thereon advertisement indicia. Additionally, any one or more of the side panels may include hand holes to facilitate the handling of the carton.

CROSS REFERENCE TO A RELATED APPLICATION

This application claims the benefit of the filing date of Provisional Patent Application Ser. No. 60/662,772, filed on Mar. 17, 2005, which is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to a collapsible-reusable-returnable-recyclable, die cut, self-locking corrugated cartons with or without die cut hand holes, which may be produced by a rotary cutting die using a 4 point knife blade having a 0.0625 inch knife width or other manners.

SUMMARY OF THE INVENTION

An aspect of the invention relates to a collapsible-reusable-returnable-recyclable, die cut, self-locking corrugated carton. This container may be used as an advertisement corrugated carton. It may be furnished with advertisements directly printed on one or more panels, with custom ads and/or logos. The container may also be manufactured on Kraft paper bags as well. The corrugated carton may include heavy duty double walls. Carton may be brown (e.g., using Kraft Paper bags), or may be brown on the inside and white on the outside, or white on the inside and white on the outside, or any other combinations thereof.

More specifically, the carton comprises a plurality of side panels attached to each other by way of respective folding lines; a plurality of bottom panels attached to respective side panels by way of another respective folding lines; wherein the side and bottom panels are adapted to lie substantially on a same plane when the carton is in an unfolded state; and wherein the side panels area adapted to form sides of the carton, the bottom panels are adapted to form a bottom of the carton, and at least a pair of the bottom panels are adapted to interlock when the carton is in a folded state. Any one or more of the panels may include advertisement indicia. Additionally, any one or more of the side panels may include hand holes to facilitate the handling of the carton.

Another aspect of the invention relates to a method of folding a carton in an unfolded state. This method is based on a carton comprising a plurality of side panels attached to each other by way of a first set of respective folding lines, and a plurality of bottom panels attached to respective side panels by way of a second set of respective folding lines, and wherein the side and bottom panels are adapted to lie substantially on a same plane when the carton is in the unfolded state. The method comprises folding the side panels along the first set of respective folding lines to form sides of the carton; then folding the bottom panels along the second set of respective folding lines to form a bottom of the carton; then interlocking at least two of the bottom panels to secure the bottom of the carton.

Yet another aspect of the invention relates to a method of unfolding a carton in a folded state. Similarly, this method is based on a carton comprising a plurality of side panels attached to each other by way of a first set of respective folding lines, and a plurality of bottom panels attached to respective side panels by way of a second set of respective folding lines. The method comprises un-interlocking at least two of the bottom panels to unsecure the bottom of the carton; then unfolding the bottom panels along the second set of respective folding lines; then unfolding the side panels along the first set of respective folding.

Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary unfolded corrugated carton in accordance with an exemplary embodiment of the invention;

FIG. 2 illustrates another exemplary unfolded corrugated carton in accordance with another embodiment of the invention;

FIG. 3 illustrates another exemplary unfolded corrugated carton in accordance with another embodiment of the invention;

FIG. 4 illustrates a top view of an exemplary folded corrugated carton in accordance with another embodiment of the invention;

FIG. 5A illustrates a bottom view of the exemplary carton at a first stage in the folding of the exemplary carton in accordance with another embodiment of the invention;

FIG. 5B illustrates a bottom view of the exemplary carton at a second stage in the folding the exemplary carton in accordance with another embodiment of the invention;

FIG. 5C illustrates a bottom view of the exemplary carton at a third stage in the folding of the exemplary carton in accordance with another embodiment of the invention; and

FIG. 5D illustrates a bottom view of the exemplary carton at a final stage in the folding of the exemplary carton in accordance with another embodiment of the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

FIG. 1 illustrates an exemplary unfolded corrugated carton 10 in accordance with an exemplary embodiment of the invention. The corrugated carton 10 is characterized as having four side panels, an open top (e.g., a half-slotted container), and a self-locking bottom. Advertising indicia may be placed on the side panels as well as on the self-locking bottom. The carton 10 may also include hand holes to facilitate the handling of the carton.

More specifically, the carton 10 comprises four side panels 12, 14, 16, and 18, and an attachment flap 20. Corrugated folding line 13 is situated between side panels 12 and 14; corrugated folding line 15 is situated between side panels 14 and 16; corrugated folding line 17 is situated between side panels 16 and 18; and corrugated folding line 19 is situated between side panel 18 and the attachment flap 20.

The carton 10 further comprises a self-locking bottom 30 including bottom panels 32, 34, 36, and 38. Corrugated folding line 33 is situated between bottom panel 32 and side panel 12; corrugated folding line 35 is situated between bottom panel 34 and side panel 14; corrugated folding line 37 is situated between bottom panel 36 and side panel 16; and corrugated folding line 39 is situated between bottom panel 38 and side panel 18. In the unfolded state, the side and bottom panels lie substantially on the same plane (i.e., the carton is generally flat). The carton 10 may have a little bend or warp if it has been folded and unfolded one or more times.

Bottom panel 32 comprises a substantially rectangular portion 32 a and a substantially triangular portion 32 b. Bottom panel 34 is essentially rectangular, but includes a pair of rectangular grooves 34 a and 34 b situated on either side of a central region. Bottom panel 36 comprises a substantially rectangular portion 36 a and a substantially triangular portion 36 b. Bottom panel 38 is essentially trapezoidal in shape, having angled edges 38 a and 38 e, and rectangular end regions 38 b and 38 c separated by a rectangular groove 38 d.

FIG. 2 illustrates an exemplary unfolded corrugated carton 10′ in accordance with an exemplary embodiment of the invention. Carton 10′ is similar to carton 10, except that carton 10′ further comprises advertisement indicia 40 on the side and bottom panels 14 and 36.

FIG. 3 illustrates an exemplary unfolded corrugated carton 10″ in accordance with an exemplary embodiment of the invention. Carton 10″ is similar to carton 10, except that carton 10″ further comprises hand holes 50 through one or more side panels 14 and 18 to facilitate the handling of the carton 10″.

FIG. 4 illustrates a top view of the exemplary folded corrugated carton 10 in accordance with another embodiment of the invention. When formed, the bottom panels 32, 34, 36, and 38 are interlaced. The rectangular end regions 38 b and 38 c of bottom panel 38 extend respectively within the grooves 34 b and 34 a of bottom panel 34; thereby, interlocking the bottom of the carton 10. The attachment flap 20 is attached to the inside wall of the side panel 12. The corrugated carton 10 has an open top.

The following describes an exemplary method of forming the carton 10.

FIG. 5A illustrates a bottom view of the exemplary carton 10 at a first stage of forming the exemplary carton 10. The carton 10 is initially folded along corrugated folding lines 13, 15, 17, and 19 such that sides 14 and 18 are substantially parallel to each other, and sides 12 and 16 are substantially parallel to each other. In addition, in the first stage, the attachment flap 20 should be situated adjacent to the inside wall of side 12. After the carton 10 is initially folded, the attachment flap 20 should be securely attached to the inside wall of the side panel 12. The attachment may be accomplished by an adhesive or a mechanical device (e.g., a relatively large staple).

FIG. 5B illustrates a bottom view of the exemplary carton 10 at a second stage in the folding of the exemplary carton 10. After the carton 10 has been folded and the flap 20 securely attached to the inside wall of the side panel 12, the first bottom panel 34 is folded upwardly (towards the interior of the carton) along corrugated folding line 35 towards the center of the bottom of the carton 10.

FIG. 5C illustrates a bottom view of the exemplary carton 10 at a third stage of forming the exemplary carton 10. After the first bottom panel 34 has been folded, the second and third bottom panels 32 and 36 are folded upwardly (towards the interior of the carton) respectively along corrugated folding lines 33 and 37 towards the center of the carton 10. In this position, respective portion of the second and third bottom panels 32 and 36 overlap with the first bottom panel 34.

FIG. 5D illustrates a bottom view of the exemplary carton at the final stage of forming the exemplary carton 10. Once the second and third bottom panels 32 and 36 are folded, the fourth bottom panel 38 is folded upwardly (towards the interior of the carton) along correlated line 39 in a manner that the end regions 38 b and 38 c of the fourth bottom panel 38 are inserted through corresponding grooves 34 b and 34 a of the first bottom panel 34. After the end regions 38 b and 38 c of the fourth bottom panel 38 are inserted through the corresponding grooves 34 b and 34 a of the first bottom panel 34, the inside of the formed bottom 30 is then pushed towards the bottom to lock the bottom 30. In the lock position, the end regions 38 b and 38 c of the fourth bottom panel 38 are situated on top of the first bottom panel 34.

The process of unfolding the carton 10 is similar to the folding process, except in the reverse direction. For example, the end regions 38 b and 38 c of the fourth bottom panel 38 are removed from the corresponding grooves 34 b and 34 a of the first bottom panel 34; thereby, un-interlocking the bottom of the carton 10. Then, the bottom panels 38, 32, 36, and 34 are unfolded downward (away from the interior of carton) along their respective corrugated folding lines 39, 33, 37, and 35. Then, the flap 20 is detached from the inside wall of the side panel 12. Then, the side panels 12, 14, 16, and 18, and flap 20 are unfolded to form the unfolded carton 10.

Although FIGS. 1-5D illustrate exemplary cartons, it shall be understood that the corrugated carton can come in any size, any shape, and any style.

In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. 

1. A carton, comprising: a first side panel; a second side panel attached to said first side panel by way of a first corrugated folding line; a third side panel attached to said second side panel by way of a second corrugated folding line; a fourth side panel attached to said third side panel by way of a third corrugated folding line; a flap attached to said fourth side panel by way of a fourth corrugated folding line; a first bottom panel attached to said first side panel by way of a firth corrugated folding line; a second bottom panel attached to said second side panel by way of a sixth corrugated folding line; a third bottom panel attached to said third side panel by way of a seventh corrugated folding line; and a fourth bottom panel attached to said fourth side panel by way of an eighth corrugated folding line; wherein said first, second, third, and fourth side and bottom panels are adapted to lie substantially on a same plane when said carton is in an unfolded state; and wherein said first and third side panels are adapted to form first opposed sides of said carton, said second and fourth side panels are adapted to form second opposed sides of said carton, said second and fourth panels are adapted to interlock and lie respectively above and below said first and third bottom panels, and said flap is adapted to lie within said carton when said carton is in a folded state.
 2. The carton of claim 1, wherein said flap is adapted to lie next to an inner wall of said first side panel when said carton is in said folded state.
 3. The carton of claim 1, wherein said flap is adapted to be attached to an inner wall of said first side panel when said carton is in said folded state.
 4. The carton of claim 3, wherein said flap is adapted to be attached to said inner wall of said first side panel by an adhesive.
 5. The carton of claim 3, wherein said flap is adapted to be attached to said inner wall of said first side panel by a mechanical device.
 6. The carton of claim 1, wherein at least one of said side panels includes an advertisement indicia.
 7. The carton of claim 1, wherein at least one of said bottom panels includes an advertisement indicia.
 8. The carton of claim 1, wherein at least one of said side panels includes a hand hole.
 9. The carton of claim 1, wherein a top portion thereof is open when said carton is in said folded state.
 10. A carton, comprising: a plurality of side panels attached to each other by way of respective folding lines; a plurality of bottom panels attached to respective side panels by way of another respective folding lines; wherein said side and bottom panels are adapted to lie substantially on a same plane when said carton is in an unfolded state; and wherein said side panels area adapted to form sides of said carton, said bottom panels are adapted to form a bottom of said carton, and at least a pair of said bottom panels are adapted to interlock when said carton is in a folded state.
 11. The carton of claim 10, further comprising a flap attached to one of said side panels by way of another folding line, wherein said flap is adapted to lie within said carton when said carton is in said folded state.
 12. The carton of claim 10, wherein said respective folding lines attaching said side panels to each other are corrugated.
 13. The carton of claim 10, wherein said respective folding lines attaching said bottom panels to said side panels are corrugated.
 14. The carton of claim 10, further comprising a flap attached to one of said side panels by way of another folding line, wherein said flap is adapted to lie abut an inner wall of another of said side panels.
 15. The carton of claim 14, wherein said flap is adapted to be attached to said inner wall of said another of said side panels.
 16. The carton of claim 10, wherein at least one of said side panels includes an advertisement indicia.
 17. The carton of claim 10, wherein at least one of said bottom panels includes an advertisement indicia.
 18. The carton of claim 10, wherein at least one of said side panels includes a hand hole.
 19. A method of folding a carton in an unfolded state, wherein said carton comprises a plurality of side panels attached to each other by way of a first set of respective folding lines, and a plurality of bottom panels attached to respective side panels by way of a second set of respective folding lines, and wherein said side and bottom panels are adapted to lie substantially on a same plane when said carton is in said unfolded state, the method comprising: folding said side panels along said first set of respective folding lines to form sides of said carton; then folding said bottom panels along said second set of respective folding lines to form a bottom of said carton; then interlocking at least two of said bottom panels to secure said bottom of said carton.
 20. The method of claim 19, further comprising: folding a flap attached to one of said side panel along another folding line; and attaching said flap to an inner wall of one of said side panels.
 21. The method of claim 19, wherein folding said bottom panels comprises folding said bottom panels towards an interior of said carton.
 22. The method of claim 19, wherein folding said bottom panels comprises: folding a first of said bottom panels along one of said second set of folding lines towards an interior of said; then folding second and third of said bottom panels along two of said second set of folding lines towards the interior of said carton, wherein said second and third bottom panels are situated on respective sides of said first bottom panel; then folding a fourth of said bottom panel along one of said second set of folding lines towards the interior of said carton, wherein said fourth bottom panel is situated opposite of said first bottom panel.
 23. The method of claim 22, wherein interlocking at least two of said bottom panels to secure said bottom of said carton comprises interlocking said first and fourth bottom panels.
 24. A method of unfolding a carton in a folded state, wherein said carton comprises a plurality of side panels attached to each other by way of a first set of respective folding lines, and a plurality of bottom panels attached to respective side panels by way of a second set of respective folding lines, the method comprising: un-interlocking at least two of said bottom panels to unsecure said bottom of said carton; then unfolding said bottom panels along said second set of respective folding lines; then unfolding said side panels along said first set of respective folding lines.
 25. The method of claim 24, further comprising detaching a flap from an inner wall of one of said side panel.
 26. The method of claim 24, wherein unfolding said bottom panels comprises unfolding said bottom panels away from an interior of said carton.
 27. The method of claim 24, wherein unfolding said bottom panels comprises: unfolding a first of said bottom panels along one of said second set of folding lines away from an interior of said carton; then unfolding second and third of said bottom panels along two of said second set of folding lines away from said interior of said carton, wherein said second and third bottom panels are situated on respective sides of said first bottom panel; then unfolding a fourth of said bottom panel along one of said second set of folding lines away from said interior of said carton, wherein said fourth bottom panel is situated opposite of said first bottom panel.
 28. The method of claim 27, wherein un-interlocking at least two of said bottom panels to unsecure said bottom of said carton comprises un-interlocking said first and fourth bottom panels. 